Art of making concrete lumber and other cementitious articles



Jan. 31, 1928.

F. S. CROZIER ART OF MAKING CONCRETE LUMBER AND OTHER CEHENTI'IIOUS ARTICLES Original Filed Jan. 2. 1926 5 Sheets-Sheet 1 IN V EN TOR A 'I'TORNEY.

Jan. 31, 1928.

Original Filed Jan. 2. 1926 5 Sheets-Sheet 2 I I l W 1 TEN TOR.

JTTO

Jan. 31, 1928.

F. s; cnozu-zn ART OF MAKING CONCRETE LUMBER AND OTHER CEMENTITIOUS ARTICLES Original Filed Jan. 2. 1926 5 Sheets-Sheet 3 Jan. 31, 1928. 1,657,566

F. s. CROZIER ART OF MAKING CONCRETE LUMBER AND OTHER CENENTITIOUS ARTICLES Original Filed Jan. 2, 1926 5 Sheets-Sheet 4 I EU EA" TOR.

Jan. 31, 1928.

F. S. CROZIER ART OF MAKING coucma'rn LUMBER AND OTHER CEIENTITIOUS ARTICLES Original Filed Jan.

A TTORN E Y.

Patented Jan. 31, 1928.

UNITED STATES PATENT OFFICE.

FLORENCE 8. OBOZIER, 03' NEW YORK, N. Y. ART OF BAKING CONOBETE LUMBER AND OTHER GEHENTITIOUS ARTICLES.

original application med January 2, 1926, Serial No. 78,983. Divided and this application filed Kay 28, 1926. Serial Io. 112,348.

This invention relates particularly to the manufacture of lumber and timber units of more or less standard sizes and shapes similar to wooden .lumber and timber units but I made of cement concrete or other cementitious mixture, for example boards, joists, studding, rafters, fenceposts, timbers etc, and other cementitious units and articles, and its chief object is to rovide a process or method which will enab e the manufacture of such cementitious units and articles of high quality and ads tability rapidly and economicall and rca y for convenient use.

This app ication is a division of my oopending application Serial No. 78,983, filed January 2, 1926, and ertains to the rocess or method of using t e apparatus disclosed in that application.

There is now in use no scientifically ideal base on which to spread stucco. Ex ended metal, wood lath wire mesh, burned brick and tile are all defective. Metal rusts. Stucco does not bend well on these surfaces.

The expansion and contraction of the stucco 2 and the base is difi'erent often causing.

cracks. Concrete stucco put on my'concrete sheathin boards bonds perfectly therewith and hot expand and contract together. They become one monolithic sheet, a fire proof overcoat on a frame house. It is ideal, concrete on concrete. It makes a frame house fire tproof without increasing its cost; ives all 0 the benefits of expensive masonry homes at the low cost of frame homes.

An object of this invention is to reduce concrete lumber units havin specie means for facilitating fastening the umber units to or in a wall or structure, a very desirable thing, especially when non-nailable concrete lumber is used. It is less important when the lumber units are made of nailable con crete, for example, c'oncretc in which coal cinders, slag, volcanic ash or coke and the like is used as the aggregate with the Portland cement. Another object is to furnish practical means for economically and rapidly producing concrete boards and other units havin special surfaces for improvin the bond 0 stucco and plaster thereto or or ornamentation and architectural a pearance or for resisting the elements, to t e end that better and more beautiful buildings will be possi- -ble and the cost of iepairs, painting, insurance, etc. be reduced.

Concrete lumber units and other articles must, degending on the quantity of cement used -an the revailing climate usually remaln undistur ed to set and bar en one to four weeks'before being used, so when a large out ut per day is made itgtakes an exceeding y large area of land to spread the product out on unless they are made one above the other from the ground or other support up and the concrete lumber or other units left m the pile undisturbed until set and hardened; and available land is scarce and costly in or near cities and on lots where houses are to be built. Therefore the best, if not the only commercially practical way is to make at least the concrete lumber units in vertical piles, referably of a plurality of supporte sub ivided horizontal layers of lastic concrete one above the other, the aycrs being separated from each other by wooden, concrete or com osition boards, or by sheet -metal, or by son preferably dry or by fabric, paper or other means preferabl covered or saturated with as halt, wax, oi tar or other means for m ing same less likely to be absorbed by or adhere to the concrete or admit 'water.

The method hereinafter described is specially intended or designed for making concrete lumber and other units in that way in piles of such separated concrete layers. To these and other ends the inventionconsists in the novel method hereinafter de scribed for making the lumber units and articles.

Referring to the drawings, Figure l is a side view of the preferred type of my improved apparatus or machine used for manufacturing concrete lumber units and other articles by my inadproved method. Figure 2 is a top view an Figure 3 an end view of the same apparatus or machine shown in Flure 1.

igs. 4;, 10, 23, 25 and 32 illustrate piles of lumber made by my method.

Fig. 5 shows some auxiliary apparatus for making piles of lumber such for instance as shown in Fig. 4:.

Figs. 6, 7, 8, 9 and 15 show my lumber incorporated in various ty of walls.

Figs. 11, 12 and 13 ow devices for outting the lumber into smaller sizes, Fig. 12 being a cross-section on line 12-12 of Fig.

Fig. 14 is a take for toughening the surface of the lumber when desired.

Figs. 16, 24, and 81 show devices for formln ornamental designs in the surface of the umber.

Figs. 17, 18, 19 and 20 show particular forms of reinforcement incoiporated in my lumber.

Figs. 21 and 22 show devices for lessen! the weight of the lumber units when desir Figs. 27, 28 and ilflshow methods moorporating fastening devices in the lumber.

Fig. 33 shows the preferred method of cutting the concrete boards into smaller units after the are hardened.

Fig. 3 shows the method of makln a large board from a plurality of sum or bonds.

Examining more in detail Fifi. 1, 2 audit, the numeral 40 designates ace 1 of the four vertical rocks that are the cornera of the machine, 42 the frame bar to which racks 40 are attached and which ties the two racks at one end together and to' the shoe or base 44 at the bottom. 46 and 48 are two acing and hrac' pipes, one telescoped inside the other for a lusting purposes and held tight by sctscrew 50, these t-yin the tops of the two end frame bars to er to help keep racks 40 vertical. A brace (not shown) extending from top of each end bar on a slant to the ground referably is also used. Pinion 52 is rigidly ed to shaft 54:, the pinion meshing with e teeth on rack 40, another pinion 52 being keyed to shaft 54 near its other end to mesh with the other rack of the pair of raclrs at one end of machine. Another shaft 54 and pimons 52 connect and operate on the two racks 40 at the other end of the machine. Each shaft 54 is provided with a spur driving so: 56 rigidly kc ed to the shaft, stop d operating in t e teeth on the circum erence of gear 56 to lock the mechanism and hold it at. any desired point in its vertical travel or after the container has been raised. Two idler rolls 62 operate on the back side of rack 40 to help keep rack 40 vertical and its teeth meshing with inion 52 and idler inion o4. Drive inion dB is rigidly keys toflrwc shaft 6; on each end of which shaft |s rigidly keyed a hand-wheel 70,- the said pinion meshing with the teeth of spur gear 66 on shaft 54.

Bearings for shafts 54 and 6B are furnished by the two housing boxes that enclose the pinions and rollers, which boxes are tied together by channel 72 to which they; are rigidly fastened, making a self-sustaining mechanical structure having free and accurate vertical movement and to which is attached vertical end wall 74 of the container and an apron attached by bolts 76,.and to which structure is removabl attached the two vertical side walls of t as container and which preferably carry removable apron 78. Preferably on or near each corneris a. vertical measurin scale to quickly indicate the inches or tainer is raised or lowered, so both ends may be moved to the same extent each time by the two operators, one at one end and one at the other end of the machine.

At each end of the machine are two slide bars 82 side by side slidably resting just below channel 72 in housings suspended from channel 72, such housings being providod with set-actews 84 for cinching the slide bars at any desired adjustment point. Near an and of each slide bar is a vertical slot 86 extending down from its top part way, in which slot slidabiy rests the vertical web of the. angle walls 60 which with its removable apron 78 comprises a vertical side wall of the container chamber of the machine. By moving the slide bars on either side of the machine out or in and IUVit ing removable and wall aprons of different desired lengths the chamber of the. container can easily and quickly be ad'nsted to make concrete layers of any desire horizontal width; and y setting the two pails ofend posts closer to ether or fart-herapart, which would cause tie sides 60 of the container to slide through slots 86in slide bars 82 and the ipes 46 and 48 to lengthen or shorten as esired, it will be iblc to malts a concrete layer of any deem-ed lei th in the container. This ready adjustabi ity is of glut practical and economic value in the art of malcin concrete lumber units, units necessarily 0 various standard widths, len ha and thicknesses.

urni hand wheel 70 rotates shaft 68 and its pinion 06 which turns spur gear 5i! to rotate shaft 54 and its two pmions 52 in unison, and as said pinions respectively mesh with the teeth on its rack, when said pinions are so turned the structure at that end of the machine must move vertically evenly, up or down as the case may he on the two end racks, carrying with it one cud of the container and its burden. Anolhcc mun, preferably at the same time, similarly op crates the mechanism at the other end of the machine. However, when side member 60 is attached with but one bearing point at each end thereof, as slot- 86, it is practicable to raise first one end of the container and then the other, to the moderate extent usually required, without undue strain.

In order that the sides and ends of the concrete layeis in the pile of layers may be longer protected against lateral displacement of the unset concrete pendin its stabilization or setting to make it sel -susmining-without lateral support, I prefer ctions thereof that the conably rovide one or more detachable or remova le extensions 88 and 90 for the side and end vertical walls of the container, and which when raised help trowel the edges of the layers and can be left on pile while necessary. Preferably these extensions are attached to the container and carried by hooks 92 tiu-nably anchored to the extension by bolt 04 or otherwise, the hook being hooked into staple or eyelet 96 on the conl-ninel'; the next extension, as the container is raised and the pile of la increases in height, is similarly alIt:iched t i; the first extension. By suitably supporting or bracing these extensions to em n place, and unhoolced them from a container, the latter can be raised independent of the extensions high enough to clear the pile, so

e entire machine can be dragged sidewlse and removed without disturbing the pile of unset concrete in em orunits and the work of building ano er similar ile near the first pile can go on at once. iis keeps the machine busy and enables rapid production in lar e quantity at low cost.

In ig. 1 the side of Sort of-a pile of my concrete boards or :er lumber units is shown in the making." 98 is the ground, 100 a sup rt for the pile of concrete lumher, 102 t e unset concrete boards or other units and 104 the paper or other means between the layers for keeping the layers from bonding together or ten ing each other until they are set.

Layers of concrete and paper are added alternately one above the other until a pile of the desired he ht is secured, as may be readily understood by referring to Figs. 4, 5 and in which the layers and forms may be seen independent of the apparatus above described.

Fig. 10 is a crude form of m apparatus that I use in some cases for m 'ng certain concrete products by my method. Preferably it consists of a plurality of removable frames 106, one above the other and surrounding a pile of a plurality of plastic concrete lcycrs or units 08 resting on support 110, the layers or units being separated from curb other by paper or other means 112. As shown part 0 each frame is broken awn to show the layers or products inside. Pre

'ber units; mostly crably each frame in openablo and adjustable, by means not shown, and is referebly of same height as the vertical tluckness of the concrete layer or article to be made therein.

Fig. 4 is a pile of hardened concrete lumboards, made by my improved method, 114 being the base or support on which the pile was made and rests, and 116 a layer of sand or other suitable inert material on which the bottom concrete layer preferably is made,- but, when desired, support 114 can be dispensed with and the pile rest on the ground or a floor. 118 Is one of two hardened concrete boards so.

one inch thick, comprising the bottom in or of tbe pile, which layer was sub-divi ed while plastic by filling the on 'or space between the ed of the two boards with dry sand or 0 er inert material or means 120 that will keep such. apart until hardened. Being made of cinder concrete or other concrete of a hind into or through which nails can be dr ven after the concrete is set and hardened, the board 118 isprovided with no fastener holes or other ial fastener means, and used as a sheathing board, it can be nailed to the wooden stu ding of a frame house, or to the joist or rafters, the same as if it was a wooden board, the edges and ends of the boards com mm the concrete sheathing bcmg preferab y um ed together with concrete mortar or other cementitious mixture so as to form one large monlithic sheet to protect against fire and weather. 122 is a sheet of paper, felt, fabric, com sition or other separatigg element, refera ly waxed, oiled or treat with asp t, tar or other cutting the layer in two and' means for making it water proof or less likel' to adhere to the hardened concrete p u and the second plastic concrete ayer is ormed thereon after it is put above the first layer. 124 are partitions that subdivide the second concrete layer of the pile into a plurality of concrete lumber units, the two lengthwise partitions, each of a vertical height of say one inch (the thickness of the layer) were inserted in place in the container with their lower edges on the pa r or other layer-separating means preferab y before the concrete was put into the container to form such subdivided concrete layer; the bdividing partition 124 was inserted preferably after the concrete layer was crowd and before it was much not or hardcnetlblgr being pushed down into the concrete to en ivide the layer into still smaller units; all these partitions 124 were left in place in tho subdivided lastic concrete layer until the concrete of t is layer was set and harde'ned, and then they were removed and used over again. 126 is a specially thick layer of dry sand or substituted inert material between two plastic concrete layers, used to keep the layers apart and to facilitate by absorption and drainage the removal of excess water from the adjacent sloppy wct concrete layers and thereafter to return to the setting concrete its stored up moisture while the concrete is hardening. The fourth concrete la er of the pile is left full size and not so ivided. 128 are sheets of metal, preferably galvanized, or of some other thing suitable or keeping the concrete layers apart. 130 are the top two less slop y wet concrete layers of the pile, each subdivided; and between sa d l y rs is a wooden board that keeps lit) them apart. 132 is one of the two vertical spaces left between the subdivisions of the concrete layer when the subdividing partitions were withdrawn preferabl before the stabilized concrete became much rdened, which see were left open and not tilled with an ng; and 18'! is a similar opener unfilled cut" or space between two units, while 136 is such a space filled with sand or substituted material. 188 are, metal reinforcing elenients imbedded in and covered by the concrete of which the board or otherunit was made. board made by imbedding in the concrete while Iastic a screw or other threaded element t at referabl is left in until the concrete is at east pa y set and hardened and then removed to leave a fastener'hole. 142

is a nail or rivet or the like, preferably with ,a head that is'inserted in the plastic concrete and later was removed .ss was to leave a fastener hole. 144 is a fastener hole that was made in the plastic concrete by inserting and withdrawing a nail, screw, rivet, bolt, punch or other hole-forming means and filling the hole with sand or substituted material or means for keepin the hole from closing or becoming disto or filled with concrete. 146 is a nut or other threaded fastener element or means that is at least rtl imhedded in a surface of a concrete E an; or other lumber unit or article while the concrete was not much if any set or hardene'd and left in rmanently, to aid or facilitate attaching e unit or article by threaded means to or in a wall or structure or to another unit or article. 148 is a fastener bole made b inserting an cylindrical metal element in t e lastic concrete unit, that is to remain int e ploduct permanently to metal-line the hole. 150 is a fastener ole for a bolt or other fastener element having a head that is to be at least partly counter-sunk in the concrete unit or article.

Fig. 5 shows one of the improved methods I em loy in maknig concrete units of certain inds, with my apparatus or machine. 152 is the container, 154 a removable frame support for partitions 158 and 15B. and am handles rigidly attached to the frame but not attached to the container. Frame 154 is itioncd inside of container 152, the tops o frame, container and partitions prefcrabl being even with each other. Partitions 56 and 158 are preferably rigidly and permanentl attache to frame 154, the weight of ramc 154 and partitions 156 and 158 being carried by container 152 on the top edge of which handles 160 rest, so that by raising container 152, frame 154 and partitions 156 and 158 are also raised, and can likewise be lowered. Prcfcrabl the vertical height of the partitions is t e same as the thickness of the concrete layer or article being made, their lower edges resting on the 140 is a fastener hole in the aper or other means on which the concrete yer is to be made by filling the spaces in the contsnier between the partitions and frame with concrete. When the subdivided layer is com leted container 152 is raised and with it me 154 until artitions 156 and 158 are out of contact wi the concrete of the layer; thenframe 154 and its partitions 150' and 158 are lifted oil from container 152 b handles 160. The cracks or open spaces sit by removing frame 154 and partitions 156 and 158 are filled with dry sand or substituted means for reventin the concrete from sagging or filling sucli spaces. The concrete layer so supported and protected is then covered with paper or other means for so porting the next concrete layer to be bui t above the first and to prevent its contact with the layer; not completed. Frame 154 and its psi-ti ions 156 and 158 are put back in the container 152 gidchlogertled until partitions 156' and 158 u c ayer-separati a or means, then the o oration is The sand or substitu means flllmgmthe space left b removal of frame 154 is pt in place by t e walls of container 152 and its extensions 162 and 164'which are held in place by books 188 and 168. The projections on partitions lliti and 158 make notches or depressions in the edges and ends of the concrete boards or other units or articles for the m:- commodation of fasteners and for other purposes. By using a. artition of suitable shape the edges of t e concrete board or article can easily be given a pleated, sawtooth or other desired form.

Fig. 6 is a cross-sectional view of a wall built of my concrete sheathing boards 172 attached by metal fasteners to steel channel studding or uprights 174, stucco being put on the outer concrete boards and plaster on the inner concrete boards, the edges of the concrete boards preferably being cemented together with concrete or other cementitious mixture. Several kinds of fastener means for attaching the concrete boards to the steel studdin joist or rafters are shown. 176 is a bolt t at extends through fastener hole 17 8 in each of the two 0 posits concret boards, one in the outer and the other in the inner sheathing course, and through two holes punched or drilled through the two well: of channel 174, 180 is a threaded out on bull. 176 n-eferably at least partly counter-sunk in lots 178, and 182 is the head of bolt 1-76 shown counter-sunk in board 172 and covered with luster 184. 186, 188 and 190 shows short ustener bolts that extend 0111 through the concrete board and one web 0 steel channel 174 and their threaded nuts. There is no chance for moisture to follow these bolts through the wall and these fasteners are more ads table for varying needs. 192 is still anot er fastener, that is cinched in tit nos-moo place or hold by clenching or bending one end as shown or otherwise. In some cases I use a wire fastener that is threaded through a hole or notch in the concrete unit or put between two units to help attach the unit to or in a structure or to another unit or article.

Fig. 7 is lmfgely the some as 6 except that rein orced concrete stud 'ng 194 containing element 196- is used in lace of steel channel. Bolt 198 goes through a remade hole in the concrete studding or 0 or unit, and bolt 200 goes through metallic cylinder or pi e 202 that is embedded in and forms a ho e through the concrete stud or unit.

Fig. 8 is a cross-section view of a wall "for a frame building having wooden studding 204 to the two opposite sides of which is mailed, screwed or otherwise fastened a plurality of concrete boards 206 to form an inner and outer fire proof concrete sheathing to protect the structure and contents and the wooden frame-work or studs against fire, weather. insects, rats, heat and cold, to increase the str and durability of the wall and when esired be an ideal base for stucco 208 and plaster cost 210; nndyrith some variations as to details floors, ceilings, roofs and partitions can be made of these concrete hoards entirely or in part largely in the some manner. In some cases I bevel the face, or the edges or ends of the concrete boards while plastic, say as at 212, to make it more certain that water will run outwardly or to better enable stucco or other cementmg agent to get in between the boards edges or ends to cement them to ether, and for architectural appearance. n some cases I slot the end or edge of a board as at 214 for fastenors 216 so it will be easier to adjust board 'in wall. Fasteners 218, 220 and 222 can be used when the boards or units are made of concrete that is not nailnble and no fastener holes have been made therein. 224 and 226 are ordinary wire nails, spikes or other driven fasteners or screws inserted in premade fastener holes in the concrete boards and then driven or screwed into the wooden stubbing, 'oist, rafter or other wooden unit. 228 is a bolt or other metal fastener that connests or ties the two concrete board sheathing walls together, preferably without going through and weakening the stubbmg. IS a joint without mortar. 232 ismotal remforcing which sometimes it is wise to unbed in the concrete board or a thick concrete plank such as preferably comprise the lowest or bottom course of the concrete board-sheathing, and which may so largely carry the weight of the concrete boards above and must prevent any settling that might cause cracks in the sheathing or the stucco or plaster thereon and let moisture in. This precaution in taunts ith when the foundation on which the buil ing rests 1s piers or posts, not solid masonry. Preferably the Weight of the concrete board sheathing is on the foundation and not on the nails or fasteners, but it safely can-be largely carried on the studding and other frame cloments when steel or reinforced concrete studs or frame are used through use of suitable attachin bolts or isstcners.

Fig. 9 is a ace view of part of a wall made of vertical wooden studdmg 283 to which is attached a sheathing composed of a galgrality of my on roved concrete boards 286 238 and united together with the aid of concrete or other cementitious mortar 242. Board 284 has a notch or depression (244 and 216) on each of its two edges and in its end, so fasteners can be used to help attach the board to the structure without having holes throu h thc'board and to enable the ends and gas of the boards to be in contact with each other or to enable use of a thm mortar-joint. l asteners 248 and 250 are in such notchcs'and each has a head that preferably extends beyond the notch to clasp or cinch and better secure the board in place or it ma be at leastggzrtly countersunk 1n the. no 252 and are fasteners with heads, to be driven, screwed or otherwise inserted between the edges or ends of two adjoining concrete boards or other units or articles that do not have fastener holes, notches or other 1: means in them, so as to secure such boards, units or articles to or in a wall or structure or to another unit or article, the'heads preferably extending over and securely mg or cracking the ends or of such ards, units or artielse. In ese cases the space between the two adjoining boards will be wider and mortar joint 2L2 thicker. 256 is a vertical slot and 258 a horizontal slot in board 240, allowing some adjustability for the fasteners that go in such slots.

Figs. 11 and 12 show a slotted ide for a knife or other tool or means used to cut or subdivide afplastic concrete layer whiloim the container 0 my a paratns or machine into a pluralit of ho s or other units or articlesan for other p 260 being the angle-irons of which preferably the guide is made, 262 the ends which n 'dly tie the angle-irons to thcr, 264 the andles, 266 the slant of t e bottoms of an o-irons set so only their front or slot edge will touch the concrete (to avoid massing up or disfiguration of the face of the concrete layer and 268 is the slot that guides the kni e etc. Fig. 18 is one kind of tool used with the device in-Figs. 11 and 12. F' 14 is a rake, preferably made (as shown by drivin a at of nails through a wood strip, use to grooveor toughen surface of my concrete ioo hoardsorotherunitsaostuccoorplaster more readil'yandsecurslybond together forotherpurpoees.

Figlli'uafaceviewof artpfawall bulltofstuddingfilgltow lasecured b fastenersmand lmyconcretehoards i oand mtheface will and Fig. 16 illustrates one or an improved methods o boards an other concrete lumber units and articles having an threaded ornamental face or a face ornamented, whereby the exterior of frame and other buildings, built preferably at least an part of in concrete lumber, may be ornamented and utified in a t vari of ways at a relatively nomina cost, and interior of buildings also; and the variety will be still further multiplied b using a diflerent color or shade of color 0 concrete, or concrete made of any one or more of many diilerentavailable :1 -1 inmakingthe concrete of which 1 least the ornamental face of the product is formed. 286 is the container in which the ornamental boards or units are made, and 2881s the pattern, metal sheet or other substance or fabric having on its face or in its weave an ornamental pattern or a design 290, stamped, carved, molded p soul tuned or otherwlse made thereon; and 2 is the concrete put in the container upon the face of such ornamental pattern or design to form the ornamented concrete units or articles. Ornad sheet metal so commonl cornicee, interior w l icturc frame moldings ighly ornamental and artistic having a face in relief or fashioned classical or other designs or pattern: are available at a relatively nominal cost for my use over and over for this purthus transferring their ornamental mental stem used for ceili decorations, an and man other or reproduch? them with slight exon the face 0 my me vs concrete stone boards that will on are forever uninjured by the ra of time or the elements. They will 11 rust like iron will, nor require or repair. Preferably I cover e u turned ornamental face of the pattern or esign when it is laid m the container with the cementitions mixture of the desired character and color and of about the consistency of whipped .cream, working the same to remove the ocketed air bubbles therefrom and to fill with the mixture all of thonooks and parts of the ornamental design or pattern; and then I put on such facing enough concrete to fill the connesaaae tainer and complete the concrete board or other lumber unit or article, and when desired I provide the product with means by one of m sereval methods herein" elsewhere described; the product being left on such pattern sl irport until it is at least partly set and he cued.

Fig. 17 is part of a concrete board or other lumber unit 294, havin a fastener hole 296 that thro 1 the unit and the met 1c reinfiorcmg element 298 that is imbedded in the unit, making a stronger fastenor means.

l ig. 18 is a concrete board or other lumber unit or article 300 in a face of which is permanently imbeddcd or held a'nut or other metallic fastener element 302 804 beluga threaded bolt, screw or other that is Klit through the object or unit to winch t board, and. or article is to be attached gas shown here, a web of a channel iron stud ing) and its threaded cml screwed into said nut or other fastener element 802 that is imbedded or held in the concrete board, unit or article.

Fig. 19 is part of a wall havi a stud 306, to each side of which is seen concrete boards 308 and 810, boards 808 having on their inner surface manentl secured thereto asphalted, oil or wax pa r or other means for keeping moisture, col heat or sound from at least so readily going through such boards, and 812 is a sheet of Such pa r or other means for the same purpose un ded in concrete board 810.

Fig. 20 is a cross-section of a wall having a reinforced concrete studding 314 containing a section of pipe or other round hollow element 316 threaded on its inner surface 318 and preferably cxtendin through stud 814, fastener screws or tllrea ed bolts 320 being inserted through fastener holes in concrete hoards'tlzll and 322 and screwed into the threads on the inner surface of said pipe 816 to secure the boards to stud 314. Fig. 21 is a board or other lumber unit 326, of some size and thickness made lighter by imbed u in the concrete thereof pastcboard hollow rolls or tubes or space-filling means 328. Fig. 22 is a similar unit 330, made lighter by imbedding in the concrete of which it is made lumps of coke, cinders, or other light or liggltening material or means 332.

'g. 28 shows a method of putting reinforcing rods or means into my reinforced concrete boards and other lumber units 334 and 836 while in container 888, that is divided by partition 340. The container is first partly filled with concrete 342 to form the lower part of the layer, on which the reinforcin elements 344 are laid in the de sired positions, the balance of the container bein then filled with concrete to imbed the rein orcing elements and com lete the layer and boards or units, which are eft to harden.

Fig. 24 shows m method of ornamenting my concrete or o er lumber units 846 by pressing mto the plastic surface thereof while in the container a wire mesh 348 or other fabric, pattern, design or other means for oruamentmg, with the aid of roller 350 or other pressing mean then stripping oil or removing such mesh, bric or at \er ornament means, preferallgg at once, suitably protecting the ornamen face against soil or disfigurement and let roduct set and harden. Fig. 25 shows :1. pi e of my concrete boards each having a special face that has been ornamented with a top layer of concrete of a difl'erent kind or color than the balance of the concrete of the board. Fi 26 shows how I make my ornamental boa or other lumber units by putting in container 852 a layer of moist sand 854 and p into the sand surface an ornamental deal 856 made by pressing-on the sand and en removing ornamental face 358 of attern 360, then covering the impressed san layer with soapy-wet concrete of the desired kind and color and on this put concrete that preferably is not so wet to fill the container and complete the unit.

Fig. 27 is a orom section view show one of my ways of m fastener loles thronh my concrete boar or other lumber units 62. Hole B64 is simply punched and left oplelili. The other hole is permanently metoled, made by inserting cylindrical element 366 in which is'metallic element 368 that preferably is not removed until after the concrete has at least partly set and hardened. 28 is a CIOSSSBOUOB of In concrete boar or other lumber unit 362, in the concreteo'f which is permanently imbedded one end of a metallic fastener element 370 to facilitate attaching the unit in a wall or to another unit or article, the other hole, 872, being designed to accommodate and at least part y counter-sink the head or nut of a bolt or other fastener. Fi 29 is a cross section of one of my concrete ards or other hunber units 362 having a special waterproof facing S'I'Land two fastener holes, 376 and 378, just made in the unset lastic concrete, hole 3 bein filled with ry sand or substituted material to keep it from being distorted before the concrete is set, then bein removed, and the other hole, 378, is left iil ed by the rivet or other means used to punch the fastener hole through the plastic concrete, which means preferably is removed after the concrete uni has atvleast partly set and hardened leaving a fastener hole of the desired shape and size at the correct predetermined spot.

Fig. 30 shows mother of my improved methods for makin an ornamental concrete board or other lum 1' unit 380 in container, 382 by carving, sculpturing or otherwise forming or fas ioning a face thexsof while plastic or at least not fully set or hardened, with the desired ornamental designs 384 and 386 or other ornamentation, in relief or otherwise, then protecting said ornamented face against blemish until hardened. Fig. 31 shows how I attach applied ornaments and 390 to my hardene concrete board or other lumber unit 892, 388 being cemented on with cementitious mortar 394 which makes a monolithic union, and 390 is nttached by the aid of fasteners 396.

Flag. 82 shows my preferred method of ma ng concrete sidewalk, floor or roof boards or plates with my improved apparatus or machine. 398 is the container, 400 a wooden or metal pattern frame, 403 in wooden or other so port for the late that is to be made, a pate like 404. irst the :gaees within the frame are packed full to e to of the frame with moist sand 406, then me 400 is removed and the 5 aces left by its removal filled with wet mix' conorete. Enough additional concrete is then put in and leveled off to cover the first concrete and the send but preferably not enough to fill the container 898, and on this concrete (when plate is to be reinforced) reinforcing element 408 is laid in proper position. Then sullicient additional concrete 404 is put in the container to fill it and cover and unbcd the reinforcing element and complete the plate. The to of the board or plate then is given any esired finish or markin r and phrotected against blemish until her cned,

en, freed of the sand, it can be marketed.

Other she d plates for walks, floors roofs can also 8: made.

Fig. 83 shows my preferred way of outtill? myt concrete boards and other lumber 1: ts a er they have hardened Groove 405 is made in unit 410 with a tool or emery or carhorundum wheel, so the unit will break straight, as at 412. Some kinds of my concretellunber units can be sawed if not too old or hard, or drilled to make fawtcner holes; but the best and cheapest way is to out. the units to final size lmd shape while the concrete is plastic or at least not much set. Fig. 34 shows my preferred method of making alarge concrete board or other lumber unit of two or more smaller boards, us 414 and 416, or other concrete lumber umts'by joinin them together monolithicoll by cemeat 18, preferably without the ai of metal fasteners.

The preferred way of practicing my herein claimed method is to form one at a time one or more relatively thin preferably horizontsl unset plastic oementitious is are made preferably of what 'is common y known as ordinary standard wet mix Portland cement concrete, each layer preferably being of approximately the same thickness as a standard wooden board orothcr lumber unit, for example a board one inch thick,

and certainly before it is much and of sufiioient length and width to make one or more cementitious bo ards or other lumber units of the desired length and width, subdividing the er preferably when made into units of a desired sire, shape and character when subdividing is desired, preferably making or placig'the layers one above the other separa by wooden, concrete or composition boards or metallic lates or sheets or dr will not absorbed b or a to concrete or by other suitab e means for keeping the layers apart and preferably also for an the layer to be made thereon, su 'vidin a lalyer when necessary or desired and pre rah y when made and the subdivisions from bonding toga or tohchi each other until at least rtly set by suits le means between the an visions removing the container or form preferably vertically and preferably without moving the layeisand preferab before the cemeutitious layers or their 'yided units have attained their maximum hardnes leaving the layers or their subdivided units on a sup portin means to set and harden so they can be handled.

I have found that a horizontal layer even as 'thin as a wooden board when made of a very wet or saturated mixture can be quickly stabilized or densified and made selfsustainin without lateral support before it is set or ardened, so the container or form usually can be removed before the concrete or other cementitious in r has to set or hardened, whereas a thicker la er of the same mixture would sag out of a pe if removed that soon and must be left in the container or form much longer, delaying the manufacture and increasing the cost of the product and requiring more equipment and a larger investment. A muchhigher pileof separated horizontal ceinentitious layers resting on each other with their lateral confining means removed before the layers have set or hardened can be made of layers of about the thickness of a wooden board or other lumber unit than would be possible if the layers are thicker. And when I facilitate such stabilization or deneification" of the layers by compacting the cementitious mixture thereof to eliminate excess water therefrom and also air and bring the cement coated particles of the mixture closer together, and when cindere or other cellular aggregate particles are used to force the air out and water into the cells of such cles, preferably by pressure or by "wor ing or manipulating the concrete or other plastic mixture of the layer while in the container or form or otherwise, I I'- new important results of distinct v us, one of' which is to store up throughout the product in the cells a! the aggreiate partides extra water needed to more t oroughly hydrate ad acmt cement, such water being fed out gradually as needed for a 10% time, therei fit'i dfiha 335 cemen e in en reduction of the amouzt used to n iake p nets of the same atren and density. And malayerasthmasa orotherlumher amt more wa er can be left in the saturated mixture without keeping the container or form on the in than would be possible if the layer was icker, and that insures more perfect hydration of the cement and a better also read:

m 'l roducee concrete lumb er strips of the desirddgiae, e, color, form, texture, fln1sh, preferably wi a res s pam wooden atri or other units for ornamen walls or o struc tures or for subdi ding moon or other surface coats and for other uses.

I claim:

1 The methpd of making concrete lumber umts, QOIIIPI'IIIIJE forming in a bottomless mold a layer 0 stic covering the top of s aid yer with nomadheeive materuhhgising the mold a distance not greater t the thiclmea of said layer plus and material, and w thin said mold and supported by said original layer.

2. The method of making-concrete lumber units, comp forming in a bottomlem mold a byesfiends concrete covering the ttgp if said la 1d m raising" emo adistancenotgreater than the thickness of said layer plus said material, and then iorming a new layer w thin said mold and supported by said original layer.

8 The invention set forth in claim 40 in which the mold is raised and the new layer formed before the 023ml layer has set.

t. The method of ing concrete lumber units compnsin forming in a bottomless mold a layer 0 plastic concrete, covering the top of said layer with non-adhesive material, raising the mold before said layer has set a distance not greater than the thickness of sa d layer plussaid material, whereby the rising mold trowels the edges of ea djayer, and then forming a new layer w thin said niold and supported by said orrgmal layer.

If. The method of melting concrete lumber units comprising forming in abottomleea mold a layer of plastic concrete, covering the top of said layer with non-adhesive material, raising the mold before said layer has set a not greater than the thickness of layer plus and material, whereby the rising mold trowels the edges of said layer then forming a-new layer within said mol then forming a new layer.

or with non-absorbent-mu and supported by said original layer, and

adding supplemental walls to the bottom of said mold whereby the ed s of said original layer are supported whi e setting.

6. The method of making concrete lumber units comprisin forming in a bottomless mold a layer 0 plastic concrete, covering the top of said layer with non-adhesive material, raising the mold before said layer has set a distance not greater than thethickness of said layer plus said material, whereby the rising mold trowels the edges of said layer, then forming a new layer within said mold and su ported by said original layer, adding supp emental walls to the bottom of said mold whereby the edges of said original layer are sup orted while setting, and in like manner a ding additional layers and supplemental walls, whereby said walls trowel and support the edges of the newly formed layers.

7. The method of making concrete lumber units comprising forming in a bottomless mold a layer of plastic concrete, covering the top of said layer with non-adhesive material, raising the mold before said layer has set a distance not greater than the thickness of said layer plus said material, whereby the rising mold trowels the edges of said layer, then forming a new layer within said mold and supported by said original layer, adding supplemental walls to the bottom 0t said mold whereby the edges of said original layer are supported while setting, and in like manner adding additional layers and supplemental walls, whereby said walls support the edges of the newly formed layers.

8. The method of making ornamental concrete lumber units comprisin forming in a bottomless mold a layer of p astic concrete, forming an ornamental face on the surface of said layer, covering the top of said layer with non-adhesive material, raising the mold a distance not greater than the thickness of said layer plus said material, and then forming a new ornamented la er within said mold and supported by sai original layer.

9. The met od of making ornamental concrete lumber units comprising forming in a bottomless mold a layer of plastic concrete, forming an ornamental face on the surface of said layer, covering the to of said layer with non-absorbent materi raising the mold a distance not greater than the thickness of said layer plus said material, and then forming a new ornamented layer within said mold and supported by said original ayer.

In testimony whereof I hereunto afiix my signature.

FLORENCE S. OROZIEB.

and supported by said original layer, and adding supplemental walls to the bottom of said mold whereby the ed es of said original layer are supported while setting.

6. The method of making concrete lumber units comprisin forming in a bottomless mold a layer of plastic concrete, covering the top of said layer with non-adhesive material, raising the mold before said layer has set a distance not greater than the thickness of said layer plus said material, whereby the rising mold trowels the edges of said layer, then forming a new layer within said mold and su ported by said original layer, adding supp emental walls to the bottom of said mold whereby the edges of said original layer are sup orted while setting, and in like manner a ding additional layers and supplemental walls, whereby said walls trowel and support the edges of the newly formed layers.

7. The method of making concrete lumber units comprising forming in a bottomless mold a layer of plastic concrete, covering the top of said layer with non-adhesive material, raising the mold before said layer has set a distance not greater than the thickness of said layer plus said material, whereby the rising mold trowels the edges of said layer, then forming a new layer within said mold and supported by said original layer, adding supplemental walls to the bottom of said mold whereby the edges of said ori 'nal layer are supported while setting, an in like manner adding additional layers and supplemental walls, whereby said walls support the edges of the newly formed layers.

8. The method of making ornamental concrete lumber units comprisin forming in a bottomless mold a layer of p astic concrete, forming an ornamental face on the surface of said layer, covering the top of said layer with non-adhesive material, raising the mold a. distance not greater than the thickness of said layer plus said material, and then forming a new ornamented layer within said mold and su ported by said original layer.

9. The met od of making ornamental concrete lumber units comprising forming in a bottomless mold a layer of plastic concrete, forming an ornamental face on the surface of said layer, covering the to of said layer with non-absorbent materia raising the mold a distance not greater than the thickness of said layer plus said material, and then forming a new ornamented layer within faid mold and supported by said original ayer.

In testimony whereof I hereunto aflix my signature.

FLORENCE S. CROZIER.

CERTIFICATE OF CORRECTION.

Patent No. 1,657, 566.

Granted January 31, 1928, to

FLORENCE S. CROZIER.

It is hereby above numbered certified that error appears in the printed specification of the patent requiring correction as follows: word "unhooked" read "unhooking"; page 5,

Page 3, line 16, for the read "studding", and page 6, line 69, for the misspelled word "sereval" read "several"; page 8,

line 107, claim 3, for "claim 40" read "claim 1'; and that the said Letters Patent should he read with these corrections therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 21st day of v February; A. D. 1928.

Seal.

M. J; Moore, Acting Commissioner of Patents.

lines 50 and 54, for the word "stubbing" CERTIFICATE OF CORRECTION.

Patent No. 1,657,566. Granted January 31, 1928, to

FLORENCE S. CROZIER.

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 3, line 16, for the word "unhooked" read "unhooking"; page 5, lines 50 and 54, for the word "stubbing" read "studding", and page 6, line 69, for the misspelled word "sereval" read "several"; page 8, line 107, claim 3, for "claim 40" read "claim 1''; and that the said Letters Patent should be read with these corrections therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 21st day oflFebruary; A. D. 1928.

M. J: Moore, Seal. Acting Commissioner of Patents. 

